Elongated rigidified container

ABSTRACT

An elongated container capable of being formed in abnormal lengths from shorter lengths of channel members having bottom and side panels, said channels being abutted to form elongated series thereof and a plurality of said series being positioned contiguously in side-by-side relation but the abutting lines of the series respectively being staggered with each other and the contiguous side panels of the adjacent series of channel members being fixedly connected to form a unitary container having a series of parallel elongated compartments rendered relatively resistant to flexing. A cover overlies the compartments and is connected thereto by any suitable means.

United States Patent 1191 Cornell et al. 229/23 BT Koehler 1 July 10, 1973 [54] 1 ELONGATED RIGIDIFIED CONTAINER [76] Inventor: William F. Koehler, P.O. Box 95, Pnmary EmmmerDavls Moorhe-ad R.D. No. 1, Hanover, Pa. 17331 A' Just 221 Flled. Apr. 5, 1972 57] ABSTRACT [2]] Appl' 241372 An elongated container capable of being formed in abnormal lengths from shorter lengths of channel mem- 229/23 229/23 has having bottom and side panels,. said channels being 136 R abutted to form elongated series thereof and a plurality [51] Int. Cl B6511 25/00 of said series being positioned contiguously in side-by- [58] Field of Search 217/6, 7; 144/ 136, side relation but the abutting lines of the series respec- /23 23 C, 3 BT tively being staggered with each other and the contiguous side panels of the adjacent series of channel mem- [56] References Cited bers being fixedly connected to form a unitary con- UNITED STATES PATENTS tainer having a series of parallel elongated comparti 1,162 524 11/1915 Stal'ey et a1. 229/1910, 4 rendered relatively resistant flexing A cover 2,2521539 8/1941 Adams 229/1310. 4' overlies the compartments and is Connected thereto y 2,661,574 12 1953 Ritter 229/23 R x y suitable means- 3,472,571 10/1969 l'limelreich......... 229/23 R X r 3,669,338 6H9 7 Claims, 11 Drawing Figures 1 PATENIEU JUL x 01m FIG. 8

l ELONGATED RIGIDIF'IED CONTAINER CROSS-REFERENCE TO RELATED APPLICATION The present invention is an improvement over the subject matter of pending application Ser. No. 55,192, filed July 15, 1970, now U.S. Pat. No. 3,669,338, issued on June 13, 1972 and in which the present applicant is a co-inventor.

BACKGROUND OF THE INVENTION The present invention pertains to a structure by which abnormally long containers, such as shipping cases, may be manufactured preferably from sheet material industrially known as hardboard or particle board, or similar material, which is less expensive than wooden lumber. In addition, when shipping or packing cases in excess of or feet in length are required, it is becoming more and more difficult to obtain lumber in such lengths and particularly lumber which can be used for such packing cases without unduly increasing the expense of the case. Thus, for example, when shipping elongated rods and tubes which need to be protected during shipment, and especially when such rods or tubes are of the order ,of 30, 40 or even 60 feet or more in length, as is not uncommon in many industries, the problem of supplying suitable shipping cases for this range of lengths of material is extremely accute.

Recent attempts to solve the problem of providing packing and shipping cases of so-called excessive lengths, that is, lengths of 20 feet or more, has resulted in the subject matter of pending application Ser. No. 55,192, filed July 15, 1970, in the names of Richard R. Cornell et al. The structure comprising such subject matter comprises a pluralityof lengths of U shaped channel members arranged in end-to-end, abutting relationship, in which said lengths of channel members is covered by another series of inverted, U-shaped channel members in which the abutting ends are staggered in relationship to the abutting ends of the U-shaped channel members enclosed therein. A series of circumferential bands or tapes are applied around the nested,

U- shaped channels at longitudinally spaced locations, whereby a single container of substantial length is capable of being formed and, when filled with elongated material, is reasonably resistant'to flexing. However, the principal difficulty resulting from using a case of this type is that when the same is placed upon a plurality of spaced supporting members, such as trestles, and the securing bands are cut, at least certain of the lengths of U-shaped channel members forming the bottom part of the container fall therefrom, thereby leaving the contents of the container unsupported and subject to being bent due to abnormal flexing, for example. Similarly, the sections forming the upper part of the case likewise disintegrate when the bands are cut and, in effect, the entire case more or less completely falls to pieces.

In view of the foregoing, not only is the contents of the case left unsupported thereby but, particularly if it is desired that the case serve as storage means while the material is gradually consumed for example, this is not possible due to the disconnection and separation of all of the U-shaped channel members composing theini tially assembled case. Therefore, a case of this type is strictly only usable as a shipping case and, as soon as the connecting bands are severed, problems of suitably supporting the contents of the case arise due to the more or less complete disintegration of the case.

The foregoing difficulties are obviated by the present invention which comprises a unitary, nondisintegrating container or case which is useful not only for shipping purposes but also for either temporary or permanent storage purposes to contain elongated articles of substantially indefinite length, even of the order material is formed from disintegrated wood fibers,

wood particles and chips, wood flakes, either with or without the use of additional vegetable fibers, all of which are bonded securely together into a hardboard by heat and pressure. Due particularly to the required method of forming this type of sheet material, it is difficult to obtain lengths thereof in excess of 10 or 12 feet in view of the fact that the material is incapable of being formed in endless sheets or panels of predetermined width for example. i

Such material is readily susceptible to lengths thereof of a predetermined width being grooved along one surface very precisely so as to form, for example, a bottom panel and two side panels which may be connected along the opposite edges of the bottom panel, the abutting surfaces of said panels preferably being beveled by the grooving process referred to above and said beveled surfaces are secured by appropriate industrial glue or cement such as epoxy cement or the equivalent. Prior to the grooving of the material, the surface of the sheet which is opposite the groove surface has elongated strips of suitable industrial binding tape applied thereto, such as by durable cement, whereby when the grooving has been completed, the tapes serve as hinge members for the side panels to be folded upwardly with respect to the opposite edges of the bottom panel. Such operations as has just been described are performed by machines comprising the subject matter of U. S. Pat. Nos. 3,322,171 and 3,456,701. The channel members utilized in the present invention are readily capable of being formed by said aforementioned machines.

SUMMARY OF THE INVENTION It is the principal object of the present invention to provide an elongated rigidificd container from non metallic sheet material which is formed into substantially U-shaped channels of certain lengths and a plurality of such channel members are arranged in end-to: end abutting relationship to form an elongated series thereof and at least a plurality of said elongated series are disposed in side-by-side, contiguous relationship in such manner that the side panels of the U-shaped members in such series are in close abutment so that the same may be cemented together, the principal improvement afforded by the present invention comprises the staggered relationship of the abutting ends of the other, whereby the side panels of one series overlie the bers secured together in side-by-side relationship so as to provide at least a pair of elongated compartments and a structure readily being susceptible to providing three or more adjacent elongated compartments for the reception of rod and tube material, for example, of substantial lengths, such lengths being substantially indeterminate in view of the fact that such containers may be formed in almost any reasonable length which is limited primarily only by means to convey and transport the containers from one locality to another.

It is a further object of the invention to provide such containers with flat cover panels which are coextensive in width and length with the container, said cover panels preferably being formed from the same material as the channel members and secured thereto by any one of a number of means including nails, screws, industrial tapes of various kinds which may be extended around the cover and container at longitudinally spaced locations, as well as metal bands of the type commonly used in packing and shipping cases, which are applied similarly at longitudinally spaced locations along such covered container.

It is still another object of the invention to secure the adjacent side panels of the plurality of series thereof in side-by-side relationship by utilizing either industrial type adhesives or cements or, if preferred, appropriate mechanical connectors such as screws, nails, staples and the like may be employed in lieu of cement.

It is a still further object of the invention to form the channel members by grooving sheets of said aforementioned material of predetermined width with beveled configurations, whereby the outermost elongated panels which comprise the sides of the channel members may be folded in vertical relationship to the intermediate, bottom-formed panel for the channel member and the durable tapes extend longitudinally along and across the connected edges of said panels whereby, when the beveled surfaces of the panels are suitably cemented, such arrangement additionally strengthens the composite container when all of the series of U-shaped members are connected together.

Still another object of the invention is to form said series of channel members in adjacent, side-by-side relationship in such manner that the ends of said series are disposed respectively in common transverse planes in order that end panels may be suitably secured to the ends of the elongated compartments of said container and thereby cooperate with the cover to maintain the contents of the container, when loaded, fully enclosed.

Details of the foregoing objects and of the invention, as well as other objects thereof, are set forth in the following specifications and illustrated in the accompanying drawings comprising a part thereof.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an exemplary elongated rigidified container embodying the principles of the present invention. 1

FIG. 2 is a transverse sectional view of the container shown in FIG. 1 as seen on the line 2-2 thereof and showing in exemplary manner a plurality of rods or tubes disposed within the elongated compartments of the container.

FIG. 3, in full lines, shows an end view of an exemplary panel comprising a sheet of material from which the container shown in the preceding figures is formed, said panel having grooves extending in from one surface thereof and the opposite surface employing tapes whereby the outermost panels or strips of said sheet of material may be folded upwardly to the position thereof shown in phantom in which position they are glued along the abutting bevelled surfaces thereof.

FIG. 4 is an end view of an exemplary channel member resulting from the operation illustrated in FIG. 3.

FIG. 5 is a top plan view of one exemplary arrangement of elongated container which embodies the invention and provides a pair of elongated compartments in side-by-side relationship.

FIG. 6 is a view similar to FIG. 5 but illustrating a container in which three elongated compartments are provided in side-by-side relationship.

FIG. 7 is an enlarged end view of the embodiment of container shown in FIG. 5 and having a cover applied to the top thereof.

FIG. 8 is a view similar to FIG. 7 but comprising an end view of the container shown in FIG. 6 and having a top panel applied thereto to cover the same.

FIG. 9 is an enlarged, fragmentary top plan view of one end of one of the elongated channel members employed in the container illustrated in FIGS. 5 and 6 and in which bevelled edges are formed on the ends of the bottom and side panels of the channel member for the reception of an end panel having edges shaped for complimentary engagement with the bevelled ends of the panels of the channel member, said view illustrating the end panel in separated relationship with respect to the end of the channel member.

FIG. 10 is a fragmentary end view of the structure shown in FIG. 9 as seen on the line l0l0.

FIG. 1 l is a somewhat diagrammatic top plan view of an exemplary container similar to those shown in FIGS.

5 and 6 but having a substantially greater length and illustrating in greater extent the adaptability of the construction to the formation of multi-elongated compartment containers of abnormal lengths.

DETAILED DESCRIPTION Referring to FIG. 1, an exemplary container is illustrated in perspective manner which embodies a compartmented body portion 12, details of which are described hereinafter, and a cover or top 14 which is applied to the top of the body portion to cover the open contents thereof. The top 14 is secured to the body portion 12 by any appropriate means, including nails, screws, staples or the like. However, as illustrated in FIG. I, a plurality of securing bands 16 extend around the assembled body portion and top at longitudinally spaced locations. The bands 16 may be of suitable industrial tape or metal strips which are applied by conventional tools capable of rendering the bands taut and secured in such taut condition by appropriatecommercial clips 18.

Referring to FIG. I, it will be seen that the body portion 12 has a plurality of elongated compartments 20 therein within which, for example, elongated tube or rod material is housed. Each compartment 20 is formed from a series of U-shaped channel members 22, the'arrangement of which is best illustrated in plan view in FIGS. 5 and 6. The preferred manner in which the channel members 22 are formed is illustrated in FIGS. 3 and 4, details of which are as follows:

The preferred material from which the channel members 22 are formed is non-metallic. Also, in view of the high cost of wooden lumber at present, as well as the lack of readily available so-called packing-box lumber in substantial lengths, it has been found that a highly acceptable type of material from which the channel members 22 may be formed comprisesindustrial paneling known, for example, as hardboard, particle board or press board, various types of which are formed from wood or other vegetable fibers intermixed with bonding resins as well as wood chips or wood flakes which also are employed and bonded with appropriate industrial resins. Sheet panels of this type are formed in various available thicknesses but due to the fact that the panels must be formed by heat and pressure between appropriate molding members, the possibility of forming such material in indefinite lengths is not presently feasible. Accordingly, material of this type is seldom longer than 12 or 16 feet. Suitable widths of such material in such lengths, as well as shorter lengths thereof, may be processed in the manner illustrated in FIG. 3 by forming precise, parallel grooves 24 which extend inward from one face thereof, the faces of said grooves preferably being precisely at 90 to each other.

Prior to forming the grooves 24 in one face of the 6. The adjacent side panels 28 of the respective series of channel members 22 are securely connected together by suitable means such as glue or cement, exemplary lines 36 of which are illustrated in exemplary manner in FIGS. 5 and 6. In addition, however, if desired, the aforementioned adjacent side panels 28 of the channel members of said elongated series thereof may be connected by other, mechanical means, such as.

respect in particular the present invention comprises a strip or panel of said material, the other face thereof has strips of industrial tapes 26 adhesively but detachably applied thereto directly opposite said grooves. Thus, when the grooves have been formed by appropriate industrial machines such as of the type comprising the subject matter of said prior patents US. Pat. Nos. 3,322,171 and 3,456,701, the sidepanels 28 may be folded upwardly from the original plane thereof into the position thereof shown in FIG. 3 in phantom, whereby the same are perpendicular to the bottom panel 30. Suitable industrial adhesive, such as epoxy cement 32 is disposed along the faces of the walls of the grooves 24 prior to folding the side panels 28 into the final position thereof. After appropriate drying or curing of the cement 32, it will be seen from FIG. 4 that a rigid U-shaped channel member is produced and the tapes 26 are removed. The dimensions of the channel member may be formed within a wide range of variations, commensurate with the type of elongated material to be contained within the compartments 20.

In order to form the exemplary elongated container shown in FIG. 5 or container 10 shown in FIG. 6, it will be seen. that is is only necessary to arrange a plurality of various lengths of the channel members 22 in end-toend abutting relationship wherein they contact each other at transverse abutting lines 34. If desired, cement may be applied to the end surfaces of the channel members 22 prior to effecting such abutting relationship. An elongated relationship of such abutting channel members22 forms an elongated series thereof. An additional plurality of such channel members is then arranged in end-to-end abutting relationship to form a second series and this is disposed in contiguous side-byside relationship with respect to the first series but the arrangement is such, in accordance with the important principle of the present invention, that the abutting lines 34 of the respective series are staggered with relationship to each other as clearly shown in FIGS. 5 and marked improvement over prior structures referred to above.

The composite, rigidified, elongated container described hereinabove and especially as illustrated in FIGS. 5 and 6, also preferably includes a cover 14 which, for example, may be formed from sheet material of the same type as that from which the side and hottompanels 28 and 30 are formed. The cover panel 14 is coextensive in width with the container, regardless of how many elongated compartments are therein. Particularly if the material of the cover panel 14 is of the same type as that from which the side and bottom panels are formed, a plurality of lengths thereof will have to be employed in end-to-end abutting relationship and under such circumstances the securing means, such as bands 16, preferably will overlie the abutting end lines of the cover panels 14.

In view of the ready availability of appropriate machinery to form the bevelled grooves 24 in the panel material for forming the channel members 22, it is also convenient to apply end panels 37 tothe elongated series of channel members 22 which are providedwith bevelled edges along the opposite sides and bottom as shown in FIGS. 9 and 10, such bevelled surfaces being complimentary to similar bevelled edges 40 formed on the ends of the side and bottom panels 28 and 30 of the channel members 22. The end panels 37 are secured to the ends of the channel members 22 by appropriate cement or otherwise. i In arranging the various lengths of the channel members 22 which are disposed in abutting relationship to form the elongated series thereof, by reference to FIGS. 5 and 6, as well as to FIG. 11, it will be seen that relatively random lengths of such channel members may be selected and included in the composite container as long as the transverse abutting lines of one series of said channel members are :not opposite the abutting lines of the adjacent series of channel members 22. Accordingly, it is conceivable that substantially no scrap pieces of said channel members will occur inasmuch as even very short lengths thereof may be utilized in the formation of such composite type of container as is described above. Also, particularly in forming the end structures of the container, adjacent series of the channel members 22 are disposed in side-by side rela tionshipfor firm connection to each other and, if nec of said series are disposed within common transverse planes for the application of, for example, end panels 37 thereto. Also, the upper surface of the side panels 28 of 'the channel members 22 preferably are all disposed within a common plane in each container so as readily to have the cover panel or panels 14 connected thereto in flat overlying relationship.

Referring to FIG. 11, an attempt has been made to illustrate somewhat in diagrammatic manner a substantially longer container 10 than has been shown in FIGS. 5 and 6 in order to afford an appreciation of the fact that very long and even relatively slim containers may be formed by utilizing the principles of the invention for purposes of packaging even limited quantities of very long material such as rods or tubes and the like.

The laminated nature of the adjacent series of channel members 22 which are firmly secured together along contiguous sides thereof result in the formation of a highly rigidified container even of very substantial lengths. Further, when the cover panel or panels 14 have been removed from the body portion of the container, said container remains intact-in order that the same may continue to be used for the storage of the contents of the material container therein, in addition to protecting the same during transportation and shipment. Such a container is far less expensive than a container of comparable length formed from conventional so-called packing-case type wooden boards. As indicated above however, the length of containers which may be made from wooden boards is limited due to the lack of available boards of suitable length to form packing cases of substantial lengths, for example, of the order of 40, 60 or even 100 feet or more. Thus, the present invention offers a substantial advance in the art of elongated containers and not only affords substantial length therein but, more importantly, provides a unitary container in both open as well as closed conditions.

While the invention has been described and illustrated in its several preferred embodiments, it should be understood that the invention is not to be limited to the precise details herein illustrated and described since the same may be carried out in other ways falling within the scope of the invention as illustrated and described.

I claim:

1. An elongated composite container of indeterminate length formed from a plurality of channel members each comprising a bottom panel and side panels connected to said bottom panel along the edges thereof and extending substantially perpendicularly therefrom,

a plurality of said channel members being abutted in end-to-end relationship to form an elongated series thereof having longitudinally spaced transverse abutment lines, at least a pair of said series being positioned in contiguous side-by-side relationship and the abutment lines of said series respectively being staggered relative to each other, whereby the side panels of oneseries overlie the abutment lines of the side panels of the adjacent series, and means fixedly connecting together the contiguously positioned side panels of said plurality of series of channel members to form a unitary container having a plurality of parallel elongated compartments adjacent each other and said connected side panels providing said container with substantial resistance to flexing.

2. The elongated container according to claim 1 further characterized by said plurality of adjacent series of channel members respectively having ends within common transverse planes, said ends of said series of channel members each having similar end members fixed thereto to close the ends of said elongated compartments, and a top cover panel coextensive in length and width with said container to close the top of said compartments.

3. The elongated container according to claim 1 in which the bottom and end panels of said channel members are formed from rigid non-metallic sheet material of substantially uniform thickness.

4. The elongated container according to claim 3 in which said bottom and side panels of said channel members are similarly bevelled along the connected edges thereof and said bevelled edges being connected by adhesive.

5. The elongated container according to claim 4 further including reinforcing tapes extending along and across the connected edges of said bottom and side panels and adhered permanently thereto.

6. The elongated container according to claim 1 in which said series of channel members are formed from panels of pressed platen fiber board and the side panels of said adjacent series of channel members being connected together by adhesive.

7. The elongated container according to claim 6 further including a cover for said container formed from the same material as the channel members thereof and connected across the top of said parallel compartments by strap-like bands extending transversely aroundsaid container and cover at longitudinally spaced locations. 

1. An elongated composite container of indeterminate length formed from a plurality of channel members each comprising a bottom panel and side panels connected to said bottom panel along the edges thereof and extending substantially perpendicularly therefrom, a plurality of said channel members being abutted in end-to-end relationship to form an elongated series thereof having longitudinally spaced transverse abutment lines, at least a pair of said series being positioned in contiguous side-by-side relationship and the abutment lines of said series respectively being staggered relative to each other, whereby the side panels of one series overlie the abutment lines of the side panels of the adjacent series, and means fixedly connecting together the contiguously positioned side panels of said plurality of series of channel members to form a unitary container having a plurality of parallel elongated compartments adjacent each other and said connected side panels providing said container with substantial resistance to flexing.
 2. The elongated container according to claim 1 further characterized by said plurality of adjacent series of channel members respectively having ends within common transverse planes, said ends of said series of channel members each having similar end members fixed thereto to close the ends of said elongated compartments, and a top cover panel coextensive in length and width with said container to close the top of said compartments.
 3. The elongated container according to claim 1 in which the bottom and end panels of said channel members are formed from rigid non-metallic sheet material of substantially uniform thickness.
 4. The elongated container according to claim 3 in which said bottom and side panels of said channel members are similarly bevelled along the connected edges thereof and said bevelled edges being connected by adhesive.
 5. The elongated container according to claim 4 further including reinforcing tapes extending along and across the connected edges of said bottom and side panels and adhered permanently thereto.
 6. The elongated container according to claim 1 in which said series of channel members are formed from panels of pressed platen fiber board and the side panels of said adjacent series of channel members being connected together by adhesive.
 7. The elongated container according to claim 6 further including a cover for said container formed from the same material as the channel members thereof and connected across the top of said parallel compartments by strap-like bands extending transversely around said container and cover at longitudinally spaced locations. 